Fine-Tuning Your Processes to Meet Today’s Industry Challenges
ARC Advisory Group’s 9th annual Process Management Academy (PMA) is scheduled for March 4-5, 2013 in Antwerp (B). The forum delivers content key to the success of any business with a focus on process or hybrid production. Whether you are in biotechnology, chemicals, food & beverages, oil & gas, pharmaceuticals or power generation, the case studies, analyses, and interactive discussions will provide you with new knowledge to help you increase the profitability and efficiency of your operations.
The two-day forum includes presentations by end users, ARC analysts and other industry experts who will share their experiences and provide an outlook on the future of automation. The agenda includes the following topics:
Continuous vs. Batch: How Technology is Helping Us to Rethink Traditional Production Methods
While some continuous processing operations are moving to batch production for faster demand response, some traditional batch processes are being turned into continuous processes for efficiency gains. How can users maintain profitability at lower utilization and running rates? Which method is right for your process?
Real-time Process Feedback
Process analytical technology (PAT) is changing the face of pharma manufacturing. Initiated by the FDA to promote better quality and higher productivity, Quality by Design (QbD) lets users build quality directly into product design and manufacturing processes rather than relying on end-of-batch quality checks. PAT and QbD provide the real-time process feedback and flexible processes that allow an out-of-spec operation to be steered back on course, reducing waste and improving efficiency.
Energy & Material Efficiency Optimization
Rising energy and raw material costs means that optimization of usage, yield and scrap has never been more important. It is not just about electricity or primary energy sources anymore. Instead, the focus has shifted to a WAGES (water, air, gas, electricity, steam) approach that is deeply rooted in the manufacturing process. In many industries, oil and gas are not only energy sources, but also a stock for production. Industry experience shows that energy and raw material usage can be optimized with the potential to save money, material and CO2.
Plant Maintenance in Process Industries
New technologies such as physical layer diagnostics, predictive analytics, and augmented reality are enabling sophisticated approaches to maintenance. One concern is still the role of the maintenance technician and his impact on plant reliability and uptime. Downtime is a major cost factor in the process industries, accounting for the equivalent of 20% of all production costs. Half of all maintenance man-hours are spent on fixing equipment following a failure, while only 18% of those hours are spent determining when equipment will fail and acting accordingly. With the increasing equipment complexity, what approaches can help industry to improve plant availability while lowering maintenance costs?
Enterprise Asset Management (EAM) in the Regulated Industries
Companies with US FDA validated processes or affected by the European Commission’s rules governing medicinal products must keep records for all inspection, maintenance, testing, and calibrations – particularly non-routine repairs performed on equipment as a result of failure and malfunction. While paper records are allowed, compliance with this media becomes costly and difficult to manage – and unacceptably painful during an inspection. The use of electronic documents and signatures for these records is preferred. The ability to create and store these records electronically has created high interest in the pharmaceutical industry for modern EAM systems.
Dedicated workshops, facilitated by ARC analysts, will focus on specific issues surrounding cyber security, Big Data and the Cloud, 3D simulation and training, as well as optimizing supply chains and demand response.
Cyber Security: Are We Safer Than Last Year?
A painful attack against automation systems of a municipal water authority occurred in November 2011. Using a version of HMI software that allowed access from the internet, a hacker hijacked a SCADA system and took control over the water utility in the City of South Houston.
One of the most important steps in implementing cyber security initiatives is raising the awareness of security issues among employees. What good are great policies and procedures when employees don’t understand them? High employee-awareness results from training sessions that address computer security in general, and the specific application to workplace architectures in particular.
This workshop will address these issues to help you increase security on site:
- • Password administration, protection and usage
- • Antivirus measures and how to react to suspicious e-mail
- • How IT staff should react to security breaches
- • Physical security of workplaces, computers and data communication
Big Data and the Cloud: Managing Process and Product Data in the Information Age
Meta data in process industries describe system design and configuration, document processes, and track production data. The use of CAD and simulation tools has drastically increased the amount of data that process manufacturers have to gather, evaluate, store and archive. How are leading manufacturers today managing the data glut? Is Cloud Manufacturing the answer?
3D Simulation and Training in Process Applications
Using modern instrumentation and controls, process operations become safer and more stable. With increasing equipment reliability and ROA requirements, duration between shutdowns become longer. When using advanced process control, plants control ‘themselves’ and the operator becomes a constraint manager and exception handler. Do operators loose their experience in manually operating, shutting down, starting up and handling emergencies? Is operator training simulation becoming a best practice?
More and more operations are unmanned and have irregular personnel interventions. 3D simulation is an emerging technology for making personnel familiar with the spatial configuration. How is this technology used? What the benefits? And how can 3D plant simulation be coupled with engineering and maintenance data?
Optimizing Supply Chains and Demand Response
For some years now scientists and visionaries have been talking about the third industrial revolution: a world in which custom products are ordered online and batch sizes reduced dramatically. Modern car manufacturing is moving closer to this model. Smaller companies such as My Müsli (custom mixed cereal) or Chocri (customized chocolate bars) are also taking it to the next level. This development will affect the complete value chain, from raw materials to the finished product, and offers producers a substantial competitive advantage. This workshop will discuss the implementation of supply chain optimization as a whole, and at the factory and application level.